ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft housing sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring Click here.

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    A0059DQ

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 4 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A0058OP

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 3 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    2. A0054VD

      Install the 2 cooler brackets with the 2 bolts and nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the cooler pipe clamp.

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    A0053QE

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 2 bolts and 2 nuts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  4. INSTALL FRONT ENGINE MOUNTING INSULATOR

    A0056IA

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 2 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  5. INSTALL ENGINE HANGER

    Click here

  6. REMOVE ENGINE STAND


    1. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  7. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  8. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY


    1. Install the clutch release with bearing cylinder assembly Click here.

  9. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  10. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  11. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  12. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  13. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Install the manual transaxle assembly Click here.

  14. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00542C

      Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. Operate the engine lifter and install the engine to the vehicle.

      CAUTION:

      Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

    3. A0052IB

      Temporarily install the front suspension crossmember with 2 new bolts.

    4. A0052TY

      Temporarily install the member brace rear RH and LH with 2 new bolts and the 4 bolts.

      Text in Illustration
      A0054DN New Bolt
      A0057VO Bolt
    5. A0054BV

      Install the engine mounting insulator LH with the through bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    6. A00536TE01

      Install the engine mounting insulator RH with the bolt and 2 nuts.

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    7. A0052IB

      Tighten the 2 front suspension member bolts.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    8. A00572YE01

      Tighten the 6 member brace rear bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }
    9. A0055TT

      Remove the 2 bolts and 2 engine hangers.

    10. Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  18. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A0058E1

      Temporarily install the front crossmember with the 4 bolts.

    2. A0057PF

      Temporarily install the front engine mounting insulator to the front engine mounting bracket with the bolt and nut.

    3. Tighten the 4 front crossmember bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    4. Tighten the front engine mounting insulator bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

  19. TIGHTEN FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00542C

      Tighten the rear engine mounting insulator bolt.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  20. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A0058YHE01

      Install the reinforcement with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order of C, B, D and A.

  21. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A0056BGE03

      Install the reinforcement with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order of C, B, D and A.

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  24. INSTALL FRONT AXLE ASSEMBLY LH


    1. Install the front axle assembly LH Click here.

  25. INSTALL FRONT AXLE ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  26. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  27. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  28. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  29. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedures described for the LH side.

  30. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  31. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  32. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  33. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  34. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  35. CONNECT WIRE HARNESS AND HOSE


    1. A0057GE

      Connect the vacuum hose.

    2. A0052AL

      Connect the connector tube hose.

    3. A0054IH

      Connect the engine wire with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    4. A005791

      Connect the engine wire with the 2 bolts and clamp.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    5. Connect the connector to the battery current sensor.

    6. A0057AP

      Attach the 2 clamps to install the wire harness, and then install the 2 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Connect the 3 wire harness connectors to the engine room No. 1 junction block.

    8. A005619

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water or other foreign matter does not get caught between the connector and other parts.

      • Make sure that the lever is securely lowered.

    9. Connect the wire harness clamp.

  36. CONNECT HEATER WATER HOSE


    1. A0052ZC

      Connect the 2 heater water hoses.

  37. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A00571X

      Connect the fuel tube connector and fuel pipe.

      Note

      Align the fuel tube connector with the pipe, and then push the fuel tube connector on until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting the connector, pull the pipe and connector to make sure that they are securely connected.

    2. A0054DM

      Attach the claw to install the No. 1 fuel pipe clamp.

  38. CONNECT NO. 1 RADIATOR HOSE


    1. A0055LKE05
      *1 Top

      Connect the radiator hose to the cylinder head.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  39. INSTALL CLUTCH HOSE


    1. A0053FE

      Connect the clutch hose and install the clip to the clutch hose.

      Note

      Install the clip as far as it will go.

    2. Using a 10 mm union nut wrench, connect the clutch hose to the flexible hose tube while holding the clutch hose.

      Torque:
      15 N*m  { 152 kgf*cm, 11 ft.*lbf }

      Note


      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

      • Do not kink or damage the clutch hose.

      • Do not allow any foreign matter such as dirt or dust to enter the clutch hose from the clip or bracket.

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

  40. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B0040OB

      Connect the control cable with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. B0040HR

      Connect the 2 transmission control cables with the 2 new clips.

    3. B0040JV

      Install the 2 clips.

  41. INSTALL BATTERY CARRIER


    1. A0055TQ

      Install the battery carrier with the 4 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    2. A00585R

      Install the radiator pipe with the 2 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

    3. Connect the 2 wire harness clamps.

  42. INSTALL BATTERY TRAY

  43. INSTALL BATTERY

  44. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A005351

      Install the battery clamp with the bolt and nut.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    2. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  45. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  46. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  47. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A00541T

      Using an E8 "TORX" socket wrench, connect the compressor assembly with pulley with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A00582HE01

      Install the 2 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Tighten the bolts and the nuts in the order shown in the illustration.

    3. Connect the connector.

  48. CONNECT NO. 2 RADIATOR HOSE


    1. A0058ZUE03
      *1 Top

      Connect the radiator hose to the water inlet.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  49. INSTALL GENERATOR ASSEMBLY

    Click here

  50. INSTALL V-RIBBED BELT

    Click here

  51. ADJUST V-RIBBED BELT

    Click here

  52. CONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A0053P1

      Install the grommet to the radiator reservoir.

    2. Connect the radiator reservoir with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  54. ADD MANUAL TRANSAXLE OIL

    Click here

  55. INSPECT MANUAL TRANSAXLE OIL

    Click here

  56. ADD ENGINE COOLANT

    Click here

  57. ADD ENGINE OIL

    Click here

  58. INSPECT FOR FUEL LEAK

    Click here

  59. INSPECT FOR COOLANT LEAK

    Click here

  60. INSPECT FOR OIL LEAK

    Click here

  61. INSPECT FOR EXHAUST GAS LEAK

    Click here

  62. INSPECT V-RIBBED BELT

    Click here

  63. INSPECT IGNITION TIMING

    Click here

  64. INSPECT ENGINE IDLE SPEED

    Click here

  65. INSPECT CO/HC

    Click here

  66. ADJUST FRONT WHEEL ALIGNMENT


    1. Adjust the front wheel alignment Click here.

  67. PERFORM CLUTCH ENGAGEMENT POINT LEARNING (for Manual Transaxle)

    Click here

  68. INSTALL NO. 2 ENGINE UNDER COVER


    1. A0054Q8

      Install the under cover with the 4 clips.

  69. INSTALL CENTER NO. 4 ENGINE UNDER COVER


    1. A00584N

      Install the under cover with the 2 clips.

  70. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  71. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the under cover LH with the 5 clips.

  72. INSTALL NO. 1 ENGINE UNDER COVER


    1. A0055OG

      Install the under cover with the 11 clips.

  73. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A0057NY

      Install the front lower bumper absorber with the 3 screws and 8 bolts.

    2. A0057MI

      Install the 4 screws and 2 bolts.

  74. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  75. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here